Revolutionizing Leak Detection and Cost Savings in Valve Predictive Maintenance

Abstract valves are essential components of safeguarding and control systems, playing a crucial role in ensuring that plants operate efficiently and safely. Valve failures can lead to significant production losses, increased maintenance (operating) costs and contribute to process safety incidents. In plants, a common technique for valve maintenance is condition-based replacement at fixed time intervals. Evaluating the condition of in-service valves that process fluids present substantial challenges, particularly when diagnostic methods requiring valve movement are impractical during plant operations. This limitation complicates future maintenance planning, often forcing maintenance teams to either schedule potentially unnecessary valve work for upcoming shutdowns or forego maintenance entirely. Delaying maintenance can lead to costly, unplanned maintenance activities, unplanned shutdowns, and operational deferments, with the associated loss of production often far exceeding the maintenance costs. To address these challenges, the use of Acoustic Emission (AE) techniques is proposed for valve condition assessment. AE techniques offer a non-intrusive and effective method for monitoring the integrity of in-service valves without requiring operational disruptions. By detecting the high-frequency waves generated by crack growth, leakage, or other structural changes within the valve, AE techniques can provide real-time diagnostic information, enabling more accurate maintenance planning and preventing costly unplanned events. This innovative approach aims to improve the reliability and efficiency of valve maintenance schedules, reduce unnecessary maintenance activities, and minimize the risk of unplanned shutdowns. The integration of AE techniques into valve condition monitoring represents a significant advancement in maintenance strategy, offering a more proactive and informed approach to ensuring the operational integrity of fluid processing systems. Hence, this paper aims to examine the effectiveness of the Acoustic Emission technique in detecting early leakage in safety and control valves when they are fully closed on-site. With an investment of around $20K in a small portable measurement device and utilizing cutting-edge Acoustic Emission technology, this project markedly reduced saleable gas loss. Achieving substantial progress toward our zero-emission objective, improving the overall maintenance cost and strategy and also slashed shutdown times by 70% while maintaining plant integrity and availability.